Clymer Honda XR600R 1991-2000, XR650L 1993-2007

Quick Reference Data ix General Information 1(29) Manual organization Warnings, cautions and notes Safety Serial numbers and information labels Fasteners Shop supplies Tools Measuring tools Electrical system fundamentals Service methods Storage Specifications Troubleshooting 30(21) Electrical component replacement Starting the engine Engine will not start Poor engine performance Fuel system Engine Engine lubrication Leakdown test Clutch Gearshift linkage Transmission Electrical testing Starting system (XR650L) Charging system (XR650L) Ignition system Front suspension and steering Rear suspension Brake system Lubrication, Maintenance and Tune-Up 51(34) Pre-ride inspection Engine oil Oil line strainer Oil strainer screen Air filter Control cable inspection and lubrication Throttle cable adjustment Choke cable adjustment (XR650L) Clutch lever adjustment Brakes Drive chain Tires and wheels Wheel bearing inspection Front fork Steering Rear suspension adjustment Rear suspension lubrication Battery (XR650L) Carburetor Fuel system Emission control system (XR650L) Spark plug Ignition timing Valve clearance adjustment Starter decompression lever adjustment (XR600R) Exhaust system Compression test Tune up Specifications Engine Top End 85(30) Cylinder head cover and camshaft Camshaft chain tensioner Cylinder head Valves and valve components Cylinder Piston, piston pin and piston rings Specifications Engine Lower End 115(31) Servicing engine in frame Engine removal/installation Starter gear assembly (XR650L) Flywheel and starter clutch (XR650L) Flywheel (XR600R) Kickstarter (XR600R) Oil pump Oil lines Oil strainer screen Primary drive gear assembly Camshaft chain and guides Crankcase and crankshaft Engine break-in Specifications Clutch and External Shift Mechanism 146(9) Clutch cable Right crankcase cover Clutch Clutch release lever External shift mechanism Specifications Transmission and Internal Shift Mechanism 155(11) Transmission Internal shift mechanism Specifications Fuel and Exhaust Systems (XR600R) 166(13) Carburetor Carburetor adjustments Throttle cable replacement Fuel tank Fuel valve Air box Crankcase breather system Exhaust system Specifications Fuel, Emission Control and Exhaust Systems (XR650L) 179(20) Carburetor Carburetor adjustments Throttle cable replacement Choke cable replacement Fuel tank Fuel valve Crankcase breather system Evaporative emission control system (California models) Pulse secondary air injection system Air box Exhaust system Specifications Electrical System (XR600R) 199(5) Electrical component replacement Electrical connectors Alternator Voltage regulator Ignition control module Pulse generator Ignition coil Headlight Taillight Engine stop switch Specifications Electrical System (XR650L) 204(23) Electrical component replacement Electrical connectors Charging system Alternator Voltage regulator/rectifier Ignition system Ignition control module Pulse generator Ignition coil Starting system Starter Starter relay Clutch diode Lighting system Switches Instrument cluster Horn Fuses Specifications Wheels, Tires and Drive Chain 227(22) Front wheel Rear wheel Front and rear hubs Wheel service Drive chain Sprockets Tires Wheel balance Specifications Front Suspension and Steering 249(22) Handlebar Handlebar grips Front fork Steering head Steering play check and adjustment Steering head bearing races Specifications Rear Suspension 271(12) Shock absorber Shock linkage Swing arm Specifications Brakes 283(26) Brake fluid Brake service Front brake pads Front brake caliper Front brake master cylinder Rear brake pads Rear brake caliper Rear brake master cylinder Brake hose replacement Brake disc Rear brake pedal Brake system draining Brake bleeding Specifications Body 309(5) Left side cover Right side cover Seat Left hand guard Right hand guard Front fender Rear fender Air shroud (XR650L) Frame guard Sidestand Specifications Index 314(7) Wiring Diagrams 321